US20050214121A1 - Layer system, and process for producing a layer system - Google Patents
Layer system, and process for producing a layer system Download PDFInfo
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- US20050214121A1 US20050214121A1 US10/957,438 US95743804A US2005214121A1 US 20050214121 A1 US20050214121 A1 US 20050214121A1 US 95743804 A US95743804 A US 95743804A US 2005214121 A1 US2005214121 A1 US 2005214121A1
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- layer
- substrate
- layer system
- interlayer
- anchoring elements
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
Definitions
- the invention relates to a layer system in accordance with the preamble of the claims, and to processes for producing a layer system in accordance with the preamble of the claims.
- protective layers are metallic corrosion-resistant layers (MCrAlX layers) or ceramic thermal barrier coatings, as well as layer systems comprising metallic corrosion-resistant layers and ceramic thermal barrier coatings.
- MrAlX layers metallic corrosion-resistant layers
- ceramic thermal barrier coatings as well as layer systems comprising metallic corrosion-resistant layers and ceramic thermal barrier coatings.
- Plasma-enhanced powder-spraying processes are used as coating processes for these coatings, on account of their relatively favorable economics.
- Layers of this type are attached to the substrate by mechanical interlocking and subsequent diffusion heat treatment. In some cases, the layer may become detached in operation in regions which are subject to high levels of loading or at unfavorable locations on the component, i.e. at locations which are subject to high mechanical loads. Flaking of the layer during operation causes damage to the base material, thereby significantly reducing the service life of the component.
- the object is achieved by a layer system in accordance with the claims and by a process for producing a layer system in accordance with the claims.
- the layer system according to the invention has separately produced anchoring means which have a very strong attachment to the substrate or to a layer arranged beneath them on the substrate and are attached to the substrate or the other layer in a different way than the layer.
- the stronger attachment of the anchoring means compared to the existing layer bonding is effected, for example, by melt-metallurgy bonding, which is produced in a separate process. Therefore, it is also possible to use the inexpensive and economical plasma-spraying process in order to apply the layer.
- FIG. 1 shows a layer system according to the prior art
- FIGS. 2, 6 , 7 , 8 show layer systems designed in accordance with the invention
- FIG. 3 shows a perspective plan view of a layer system configured in accordance with the invention
- FIG. 4 shows steps involved in a process according to the invention
- FIG. 5 shows steps involved in another process according to the invention
- FIG. 9 shows a gas turbine
- FIG. 10 shows a combustion chamber
- FIG. 1 shows a layer system according to the prior art.
- the layer system has a substrate 4 .
- the substrate 4 may be metallic or ceramic and in the case of gas turbine components is produced in particular from an iron-, nickel- or cobalt-based superalloy.
- At least one layer 7 , 9 (two layers in FIGS. 6, 7 , 8 ) is present on the substrate 4 .
- This may be a metallic and/or ceramic layer 7 , 9 .
- a metallic corrosion-resistant layer 7 ( FIGS. 6, 7 , 8 ) of type MCrAlX is applied to the substrate 4 , and then in addition an outer thermal barrier coating 9 , for example a ceramic thermal barrier coating 9 ( FIGS. 6, 7 , 8 ), is also applied.
- the interlayer 7 is attached to the substrate 4 , or the layers 7 , 9 are attached to one another, purely by mechanical interlocking (surface roughness) to the underlying surface, followed by a diffusion heat treatment, in accordance with the prior art.
- FIG. 2 which proceeds from FIG. 1 , shows a layer system 1 according to the invention.
- Anchoring means 10 , 13 are present on the surface 5 of the substrate 4 .
- the anchoring means 10 , 13 have a form of attachment to the surface 5 which results in an increased attachment force (more accurately: force per unit contact area) to the surface 5 compared to the form of attachment of the interlayer 7 to the surface 5 .
- the anchoring means 10 , 13 are attached to the substrate 4 , by way of example, by melt metallurgy by means of a suitably executed laser welding process. It is also conceivable for the layer 7 to be applied at defined locations by laser cladding (laser powder coating), so as to form anchoring means 10 , 13 .
- the anchoring means 10 , 13 may also be cast on or produced integrally during casting of the substrate 4 .
- the anchoring means 10 , 13 form bonding bridges for the layer 7 , 9 surrounding the anchoring means 10 , 13 .
- the anchoring means 10 may extend from the surface 5 of the substrate 4 to the outer surface 8 of the interlayer 7 , or alternatively the anchoring means 13 may be covered by the layer 7 , so that the anchoring means 13 do not extend all the way to the surface 8 of the layer 7 , i.e. are arranged so as to end within the layer 7 , 9 .
- the anchoring means 13 extend at least 10%, 20%, 30%, 40% of the thickness of the layer 7 , 9 into the layer 7 , 9 .
- the anchoring means 10 , 13 are, for example, only present locally, i.e. in a spatially delimited manner ( FIG. 3 ) on the substrate 4 or the layer 7 , specifically wherever the mechanical loading is highest. This is, for example, the region of the leading edge of a turbine blade or vane 120 , 130 . The remainder of the blade or vane would then not have any anchoring means.
- FIG. 3 shows a plan view of a surface 8 of a layer 7 .
- the anchoring means 13 which do not extend all the way to the surface 8 of the layer 7 , are indicated by dashed lines.
- the anchoring means 10 , 13 may have various geometries on the surface 5 , for example circles, stitch seams (i.e. elongate and crossing one another), wavy shapes, parallel paths and combinations thereof.
- FIG. 6 shows a further layer system 1 formed in accordance with the invention.
- the layer system 1 comprises a substrate 4 and two layers 7 , 9 .
- the interlayer 7 is, for example, a metallic MCrAlX layer, and the outer layer 9 is, for example, a ceramic thermal barrier coating 9 on the interlayer 7 .
- Anchoring means 10 , 13 are present both in the interlayer 7 and in the outer layer 9 .
- the interlayer 7 does not have to have anchoring means 10 , 13 in the sense of the present invention ( FIG. 8 ). Equally, the anchoring means may be present only in the interlayer 7 ( FIG. 7 ).
- the anchoring means 10 , 13 in the layers 7 , 9 may extend from the surface 5 , 8 of the substrate 4 or the interlayer 7 to the outer surface 8 , 16 of the layer 7 , 9 or may be covered by the layers 7 , 9 , so that the anchoring means 13 do not extend all the way to the surface 8 , 16 of the layers 7 , 9 .
- the anchoring means 10 , 13 in the interlayer 7 improve the attachment of the interlayer 7 to the substrate 4 .
- the material of the anchoring means 10 in the layer 7 may, for example, also be selected in such a way as to produce improved bonding of the outer layer 9 to the anchoring means 10 ( FIG. 7 ).
- the material of the anchoring means 10 in the interlayer 7 it is possible for the material of the anchoring means 10 in the interlayer 7 to be ceramic, so that the ceramic thermal barrier coating 9 can be more successfully joined to the anchoring means 10 , which extend as far as the surface 8 of the interlayer 7 , or the anchoring means 10 serve as a growth nucleus, in particular for epitaxial growth, when the interlayer 7 is being coated with the ceramic material of the outer layer 9 .
- the material composition of the anchoring means 10 , 13 in the layers 7 , 9 is selected appropriately according to the particular requirements.
- the anchoring means 10 , 13 are present in particular in highly thermally and/or mechanically loaded regions.
- the layer system 1 is, for example, a component of a gas turbine 100 ( FIG. 9 ) (or aircraft turbine) or a steam turbine.
- Components of the turbines which are subject to high thermal loads have a layer system of this type, for example turbine blades or vanes 120 , 130 , linings 155 of a combustion chamber 110 and further parts of housing which are located along the flow path of a hot steam or hot gas.
- the layer system 1 may be applied to a newly produced component and to components which have been refurbished after use. In this case, degraded layers are first removed from the components, any cracks are repaired and the substrate 4 is then recoated.
- FIG. 7 shows a further exemplary embodiment of a layer system 1 according to the invention.
- the anchoring means 10 , 13 are present only in the interlayer 7 .
- the outer layer 9 is present on the interlayer 7 .
- a contact surface of the anchoring means 10 at the surface 8 improves the bonding of the outer layer 9 compared to a comparable contact surface with the interlayer 7 .
- This is achieved, for example, by virtue of the fact that the contact surfaces of the anchoring means 10 at the surface 8 form nucleus points for, for example, epitaxial growth of an outer layer 9 on the interlayer 7 .
- an improved layer system 1 is achieved by virtue of the fact that the anchoring means 10 , 13 lead to improved attachment of the outer layer 9 to the substrate 4 .
- FIG. 8 shows a further exemplary embodiment of a layer system 1 according to the invention.
- the anchoring means 10 , 13 are present only in the outer layer 9 , i.e. they are present on the interlayer 7 and lead to improved attachment of the outer layer 9 to the underlying interlayer 7 .
- the anchoring means 10 , 13 are then bonded to the surface 8 of the interlayer 7 .
- FIG. 4 shows, by way of example, steps involved in a process according to the invention for producing a layer system 1 .
- the at least one layer 7 , 9 is applied in a known way to the substrate 4 or to a layer which is already present on the substrate.
- the layer 7 , 9 is treated with a laser 16 or an electron beam gun 16 , which emits a corresponding laser or electron beam 19 .
- This form of treatment causes the material of the layer 7 , 9 to be locally transformed, for example melted, all the way down to the surface 5 , 8 of the substrate 4 or the interlayer 7 , resulting in melt-metallurgy attachment of material from the layer 7 , 9 to the substrate 4 or a layer which has already been applied thereto.
- This process produces anchoring means 10 which extend from the surface 5 , 8 to the surface 8 , 16 of the layer 7 , 9 .
- the anchoring means 10 are, for example, columnar in form, and may also be designed with a concave or convex curvature ( FIG. 7 ).
- FIG. 5 shows a further example of a process according to the invention.
- first of all the anchoring means 10 , 13 are applied to the substrate 4 or the layer 7 , i.e. are produced separately. This can be effected in various ways, such as for example by a suitably executed laser welding process or laser cladding.
- the anchoring means 10 , 13 have a very strong, in particular melt-metallurgy attachment to the surface 5 , 8 of the substrate 4 or of the interlayer 7 .
- the anchoring means 10 , 13 may also have been produced during the production of the substrate 4 , for example by means of a casting process.
- the layer 7 , 9 is applied, with the anchoring means 10 , 13 being surrounded by the material of the layer 7 , 9 and forming bonding bridges for the layer 7 , 9 .
- the material of the anchoring means 10 , 13 may be the same as the material of the layer 7 , 9 , the same as the material of the substrate 4 or the same as the material of a following layer, or may also have a different material composition.
- the material of the anchoring means 10 , 13 in the layer 7 does not necessarily have to be identical to the material of the substrate 4 .
- FIG. 9 shows a longitudinal part-section through a gas turbine 100 .
- the gas turbine 100 has a rotor 103 which is mounted rotatably about an axis of rotation 102 and is also referred to as the turbine rotor.
- the annular combustion chamber 106 is in communication with an, for example, annular hot-gas duct 111 , where, by way of example, four turbine stages 112 , connected in series, form the turbine 108 .
- Each turbine stage 112 is formed from two bladed rings.
- a row 125 formed from rotor blades 120 follows a row 115 of guide vanes in the hot-gas duct 111 .
- the guide vanes 130 are secured to the stator 143 , whereas the rotor blades 120 belonging to a row 125 are arranged on the rotor 103 by means of a turbine wheel 133 .
- a generator or a machine (not shown) is coupled to the rotor 103 .
- the compressed air provided at the turbine-side end of the compressor 105 is passed to the burners 107 , where it is mixed with a fuel.
- the mixture is then burnt in the combustion chamber 110 , so as to form the working medium 113 .
- the working medium 113 flows along the hot-gas duct 111 , past the guide vanes 130 and the rotor blades 120 .
- the working medium 113 expands at the rotor blades 120 , transferring its momentum, so that the rotor blades 120 drive the rotor 103 and the latter drives the machine coupled to it.
- the components which are exposed to the hot working medium 113 are subject to thermal loads while the gas turbine 100 is operating.
- the guide vane 130 has a guide vane root (not shown here) facing the inner housing 138 of the turbine 108 and a guide vane head on the opposite side from the guide vane root.
- the guide vane head faces the rotor 103 and is fixed to a securing ring 140 of the stator 143 .
- FIG. 10 shows a combustion chamber 110 of a gas turbine 100 .
- the combustion chamber 110 is configured, for example, as what is known as an annular combustion chamber, in which a multiplicity of burners 102 , arranged around the turbine shaft 103 in the circumferential direction, open out into a common combustion chamber space.
- the combustion chamber 110 as a whole is configured as an annular structure positioned around the turbine shaft 103 .
- the combustion chamber 110 is designed for a relatively high temperature of the working medium M of approximately 1000° C. to 1600° C.
- the combustion chamber wall 153 is provided, on its side facing the working medium M, with an inner lining formed from heat shield elements 155 .
- each heat shield element 155 is equipped with a particularly heat-resistant protective layer or is made from material which is able to withstand high temperatures.
- a cooling system is provided for the heat shield elements 155 and/or for the holding elements thereof.
Abstract
On account of their form of coating, layer systems according to the prior art often only have a low level of attachment to the substrate. The layer may then become detached in the event of high mechanical loads being applied to the components. The layer system according to the invention has separately produced anchoring means which are more strongly attached to the substrate than the attachment of the layer to the substrate.
Description
- This application claims priority of the European application No. 03022540.3 EP filed Oct. 10, 2003, which is incorporated by reference herein in its entirety.
- The invention relates to a layer system in accordance with the preamble of the claims, and to processes for producing a layer system in accordance with the preamble of the claims.
- Nowadays, components which are to be exposed to high temperatures are generally provided with protective layers. These may be metallic corrosion-resistant layers (MCrAlX layers) or ceramic thermal barrier coatings, as well as layer systems comprising metallic corrosion-resistant layers and ceramic thermal barrier coatings. Plasma-enhanced powder-spraying processes are used as coating processes for these coatings, on account of their relatively favorable economics. Layers of this type are attached to the substrate by mechanical interlocking and subsequent diffusion heat treatment. In some cases, the layer may become detached in operation in regions which are subject to high levels of loading or at unfavorable locations on the component, i.e. at locations which are subject to high mechanical loads. Flaking of the layer during operation causes damage to the base material, thereby significantly reducing the service life of the component.
- Therefore, it is an object of the invention to provide a layer system and a process for producing a layer system with better attachment of a protective layer to a substrate and/or of layers to one another.
- The object is achieved by a layer system in accordance with the claims and by a process for producing a layer system in accordance with the claims.
- The layer system according to the invention has separately produced anchoring means which have a very strong attachment to the substrate or to a layer arranged beneath them on the substrate and are attached to the substrate or the other layer in a different way than the layer.
- The stronger attachment of the anchoring means compared to the existing layer bonding (e.g. mechanical interlocking provided by surface roughness) is effected, for example, by melt-metallurgy bonding, which is produced in a separate process. Therefore, it is also possible to use the inexpensive and economical plasma-spraying process in order to apply the layer.
- Further advantageous measures are listed in the subclaims.
- The measures listed in the subclaims can advantageously be combined with one another. In the drawing:
-
FIG. 1 shows a layer system according to the prior art, -
FIGS. 2, 6 , 7, 8 show layer systems designed in accordance with the invention, -
FIG. 3 shows a perspective plan view of a layer system configured in accordance with the invention, -
FIG. 4 shows steps involved in a process according to the invention, -
FIG. 5 shows steps involved in another process according to the invention, -
FIG. 9 shows a gas turbine, and -
FIG. 10 shows a combustion chamber. -
FIG. 1 shows a layer system according to the prior art. The layer system has asubstrate 4. Thesubstrate 4 may be metallic or ceramic and in the case of gas turbine components is produced in particular from an iron-, nickel- or cobalt-based superalloy. - At least one
layer 7, 9 (two layers inFIGS. 6, 7 , 8) is present on thesubstrate 4. This may be a metallic and/orceramic layer - For turbine blades or
vanes 120, 130 (FIG. 9 ), by way of example, a metallic corrosion-resistant layer 7 (FIGS. 6, 7 , 8) of type MCrAlX is applied to thesubstrate 4, and then in addition an outerthermal barrier coating 9, for example a ceramic thermal barrier coating 9 (FIGS. 6, 7 , 8), is also applied. - The
interlayer 7 is attached to thesubstrate 4, or thelayers -
FIG. 2 , which proceeds fromFIG. 1 , shows alayer system 1 according to the invention. Anchoring means 10, 13 are present on thesurface 5 of thesubstrate 4. The anchoring means 10, 13 have a form of attachment to thesurface 5 which results in an increased attachment force (more accurately: force per unit contact area) to thesurface 5 compared to the form of attachment of theinterlayer 7 to thesurface 5. - The anchoring means 10, 13 are attached to the
substrate 4, by way of example, by melt metallurgy by means of a suitably executed laser welding process. It is also conceivable for thelayer 7 to be applied at defined locations by laser cladding (laser powder coating), so as to form anchoring means 10, 13. The anchoring means 10, 13 may also be cast on or produced integrally during casting of thesubstrate 4. The anchoring means 10, 13 form bonding bridges for thelayer surface 5 of thesubstrate 4 to theouter surface 8 of theinterlayer 7, or alternatively the anchoring means 13 may be covered by thelayer 7, so that the anchoring means 13 do not extend all the way to thesurface 8 of thelayer 7, i.e. are arranged so as to end within thelayer layer layer - The anchoring means 10, 13 are, for example, only present locally, i.e. in a spatially delimited manner (
FIG. 3 ) on thesubstrate 4 or thelayer 7, specifically wherever the mechanical loading is highest. This is, for example, the region of the leading edge of a turbine blade orvane -
FIG. 3 shows a plan view of asurface 8 of alayer 7. In this illustration, the anchoring means 13, which do not extend all the way to thesurface 8 of thelayer 7, are indicated by dashed lines. The anchoring means 10, 13 may have various geometries on thesurface 5, for example circles, stitch seams (i.e. elongate and crossing one another), wavy shapes, parallel paths and combinations thereof. -
FIG. 6 shows afurther layer system 1 formed in accordance with the invention. - The
layer system 1 comprises asubstrate 4 and twolayers - The
interlayer 7 is, for example, a metallic MCrAlX layer, and theouter layer 9 is, for example, a ceramicthermal barrier coating 9 on theinterlayer 7. - Anchoring means 10, 13 are present both in the
interlayer 7 and in theouter layer 9. - However, the
interlayer 7 does not have to have anchoring means 10, 13 in the sense of the present invention (FIG. 8 ). Equally, the anchoring means may be present only in the interlayer 7 (FIG. 7 ). - The anchoring means 10, 13 in the
layers surface substrate 4 or theinterlayer 7 to theouter surface layer layers surface layers - The anchoring means 10, 13 in the
interlayer 7 improve the attachment of theinterlayer 7 to thesubstrate 4. The material of the anchoring means 10 in thelayer 7 may, for example, also be selected in such a way as to produce improved bonding of theouter layer 9 to the anchoring means 10 (FIG. 7 ). By way of example, it is possible for the material of the anchoring means 10 in theinterlayer 7 to be ceramic, so that the ceramicthermal barrier coating 9 can be more successfully joined to theanchoring means 10, which extend as far as thesurface 8 of theinterlayer 7, or the anchoring means 10 serve as a growth nucleus, in particular for epitaxial growth, when theinterlayer 7 is being coated with the ceramic material of theouter layer 9. - The material composition of the anchoring means 10, 13 in the
layers - The anchoring means 10, 13 are present in particular in highly thermally and/or mechanically loaded regions.
- The
layer system 1 is, for example, a component of a gas turbine 100 (FIG. 9 ) (or aircraft turbine) or a steam turbine. Components of the turbines which are subject to high thermal loads have a layer system of this type, for example turbine blades orvanes linings 155 of acombustion chamber 110 and further parts of housing which are located along the flow path of a hot steam or hot gas. - The
layer system 1 may be applied to a newly produced component and to components which have been refurbished after use. In this case, degraded layers are first removed from the components, any cracks are repaired and thesubstrate 4 is then recoated. -
FIG. 7 shows a further exemplary embodiment of alayer system 1 according to the invention. In thislayer system 1, the anchoring means 10, 13 are present only in theinterlayer 7. Theouter layer 9 is present on theinterlayer 7. A contact surface of the anchoring means 10 at thesurface 8 improves the bonding of theouter layer 9 compared to a comparable contact surface with theinterlayer 7. This is achieved, for example, by virtue of the fact that the contact surfaces of the anchoring means 10 at thesurface 8 form nucleus points for, for example, epitaxial growth of anouter layer 9 on theinterlayer 7. Even without an interlayer 7 (FIGS. 4, 5 , right), animproved layer system 1 is achieved by virtue of the fact that the anchoring means 10, 13 lead to improved attachment of theouter layer 9 to thesubstrate 4. -
FIG. 8 shows a further exemplary embodiment of alayer system 1 according to the invention. In this exemplary embodiment, the anchoring means 10, 13 are present only in theouter layer 9, i.e. they are present on theinterlayer 7 and lead to improved attachment of theouter layer 9 to theunderlying interlayer 7. The anchoring means 10, 13 are then bonded to thesurface 8 of theinterlayer 7. -
FIG. 4 shows, by way of example, steps involved in a process according to the invention for producing alayer system 1. In a first step, the at least onelayer substrate 4 or to a layer which is already present on the substrate. - The
layer laser 16 or anelectron beam gun 16, which emits a corresponding laser orelectron beam 19. This form of treatment causes the material of thelayer surface substrate 4 or theinterlayer 7, resulting in melt-metallurgy attachment of material from thelayer substrate 4 or a layer which has already been applied thereto. This process produces anchoring means 10 which extend from thesurface surface layer - The anchoring means 10 are, for example, columnar in form, and may also be designed with a concave or convex curvature (
FIG. 7 ). -
FIG. 5 shows a further example of a process according to the invention. - In a first step, first of all the anchoring means 10, 13 are applied to the
substrate 4 or thelayer 7, i.e. are produced separately. This can be effected in various ways, such as for example by a suitably executed laser welding process or laser cladding. The anchoring means 10, 13 have a very strong, in particular melt-metallurgy attachment to thesurface substrate 4 or of theinterlayer 7. - However, the anchoring means 10, 13 may also have been produced during the production of the
substrate 4, for example by means of a casting process. - In a subsequent process, the
layer layer layer - The material of the anchoring means 10, 13 may be the same as the material of the
layer substrate 4 or the same as the material of a following layer, or may also have a different material composition. The material of the anchoring means 10, 13 in thelayer 7 does not necessarily have to be identical to the material of thesubstrate 4. -
FIG. 9 shows a longitudinal part-section through agas turbine 100. In its interior, thegas turbine 100 has arotor 103 which is mounted rotatably about an axis ofrotation 102 and is also referred to as the turbine rotor. Anintake housing 104, acompressor 105, a for example torus-like combustion chamber 110, in particular anannular combustion chamber 106, having a plurality of coaxially arrangedburners 107, aturbine 108 and the exhaust-gas housing 109 follow one another along therotor 103. Theannular combustion chamber 106 is in communication with an, for example, annular hot-gas duct 111, where, by way of example, fourturbine stages 112, connected in series, form theturbine 108. Eachturbine stage 112 is formed from two bladed rings. As seen in the direction of flow of a workingmedium 113, arow 125 formed fromrotor blades 120 follows arow 115 of guide vanes in the hot-gas duct 111. - The guide vanes 130 are secured to the
stator 143, whereas therotor blades 120 belonging to arow 125 are arranged on therotor 103 by means of aturbine wheel 133. A generator or a machine (not shown) is coupled to therotor 103. - While the
gas turbine 100 is operating,air 135 is sucked in through theintake housing 104 and compressed by thecompressor 105. The compressed air provided at the turbine-side end of thecompressor 105 is passed to theburners 107, where it is mixed with a fuel. The mixture is then burnt in thecombustion chamber 110, so as to form the workingmedium 113. From there, the workingmedium 113 flows along the hot-gas duct 111, past theguide vanes 130 and therotor blades 120. The workingmedium 113 expands at therotor blades 120, transferring its momentum, so that therotor blades 120 drive therotor 103 and the latter drives the machine coupled to it. - The components which are exposed to the hot working
medium 113 are subject to thermal loads while thegas turbine 100 is operating. The guide vanes 130 androtor blades 120 of thefirst turbine stage 112, as seen in the direction of flow of the workingmedium 113, as well as the heat shield bricks lining theannular combustion chamber 106, are subjected to the highest thermal loads. To be able to withstand the prevailing temperatures, these components are cooled by means of a coolant. It is also possible for the blades andvanes - The
guide vane 130 has a guide vane root (not shown here) facing theinner housing 138 of theturbine 108 and a guide vane head on the opposite side from the guide vane root. The guide vane head faces therotor 103 and is fixed to a securingring 140 of thestator 143. -
FIG. 10 shows acombustion chamber 110 of agas turbine 100. Thecombustion chamber 110 is configured, for example, as what is known as an annular combustion chamber, in which a multiplicity ofburners 102, arranged around theturbine shaft 103 in the circumferential direction, open out into a common combustion chamber space. For this purpose, thecombustion chamber 110 as a whole is configured as an annular structure positioned around theturbine shaft 103. - To achieve a relatively high efficiency, the
combustion chamber 110 is designed for a relatively high temperature of the working medium M of approximately 1000° C. to 1600° C. To allow a relatively long operating time to be achieved even under these operating parameters which are unfavorable for the materials, thecombustion chamber wall 153 is provided, on its side facing the working medium M, with an inner lining formed fromheat shield elements 155. On the working medium side, eachheat shield element 155 is equipped with a particularly heat-resistant protective layer or is made from material which is able to withstand high temperatures. Moreover, on account of the high temperatures in the interior of thecombustion chamber 110, a cooling system is provided for theheat shield elements 155 and/or for the holding elements thereof.
Claims (23)
1-19. (canceled)
20. A turbine component adapted for use in a turbine engine having a layer system, comprising:
a substrate having a first surface and a second surface;
an outer layer having a first surface and a second surface, the first surface of the outer layer located on the second surface of the substrate; and
an interlayer located between the second surface of the substrate and the second surface of the outer layer having an anchoring element in the interlayer and the outer layer.
21. The layer system as claimed in claim 20 , wherein a form of attachment of the anchoring element to the second surface of the substrate and the second surface of the outer layer that adjoins the outer layer is different than the form of attachment of the outer layer or the interlayer to the second surface of the substrate and the second surface of the outer layer.
22. The layer system as claimed in claim 20 , wherein the anchoring elements extend to the second surface of the outer layer.
23. The layer system as claimed in claim 20 , wherein the anchoring elements are present on the substrate and on the interlayer.
24. The layer system as claimed in claim 20 , wherein the anchoring elements are present only on the substrate.
25. The layer system as claimed in claim 20 , wherein the anchoring elements are present only on the interlayer.
26. The layer system as claimed in claim 24 , wherein the layer system includes an interlayer and an outer layer.
27. The layer system as claimed in claim 20 , wherein the anchoring elements have a form of attachment to the second surface of the substrate, the second surface of the outer layer, or of the interlayer that has a higher attachment force to said surfaces than the form of attachment of the layer to said surfaces.
28. The layer system as claimed in claim 20 , wherein the anchoring elements are joined to the substrate and the interlayer by melt metallurgy.
29. The layer system as claimed in claim 20 , wherein the anchoring elements are joined to the substrate or the interlayer by melt metallurgy.
30. The layer system as claimed in claim 20 , wherein the material of the anchoring elements and the layer are the same.
31. The layer system as claimed in claim 20 , wherein the material of the anchoring elements is different than the material of the layer.
32. The layer system as claimed in claim 20 , wherein the anchoring elements are present in locally delimited form on the substrate or the interlayer.
33. The layer system as claimed in claim 20 , wherein the anchoring elements are columnar in form.
34. The layer system as claimed in claim 20 , wherein the layer system is a component of a gas turbine or steam turbine.
35. The layer system as claimed in claim 34 , wherein the component is a turbine blade or vane, a combustion chamber lining or a housing part situated along the flow path of a hot gas.
36. The layer system as claimed in claim 34 , wherein the component has no operating life.
37. The layer system as claimed in claim 34 , wherein the component is a refurbished component.
38. A process for producing a layered turbine component, comprising:
applying at least one layer on a substrate or an interlayer; and
placing anchoring elements in the layer.
39. The process as claimed in claim 38 , wherein the anchoring elements are produced by a laser welding process.
40. The process as claimed in claim 38 , wherein the anchoring elements are produced by electron irradiation.
41. The process as claimed in claim 38 , wherein the anchoring elements are produced having a melt-metallurgy attachment to the substrate or the interlayer.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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EP03022540A EP1522604B1 (en) | 2003-10-02 | 2003-10-02 | Layer system and process for its production |
EP03022540.3EP | 2003-10-10 |
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Publication Number | Publication Date |
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US20050214121A1 true US20050214121A1 (en) | 2005-09-29 |
US7182580B2 US7182580B2 (en) | 2007-02-27 |
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US10/957,438 Expired - Fee Related US7182580B2 (en) | 2003-10-02 | 2004-10-01 | Layer system, and process for producing a layer system |
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US (1) | US7182580B2 (en) |
EP (1) | EP1522604B1 (en) |
DE (1) | DE50306521D1 (en) |
Cited By (2)
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EP2789597A1 (en) * | 2013-04-12 | 2014-10-15 | Alstom Technology Ltd | Configuration for joining a ceramic thermal insulating material to a metallic structure |
US20150033561A1 (en) * | 2013-08-01 | 2015-02-05 | Gerald J. Bruck | Laser melt particle injection hardfacing |
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US8382436B2 (en) * | 2009-01-06 | 2013-02-26 | General Electric Company | Non-integral turbine blade platforms and systems |
US8262345B2 (en) * | 2009-02-06 | 2012-09-11 | General Electric Company | Ceramic matrix composite turbine engine |
US8453327B2 (en) * | 2010-02-05 | 2013-06-04 | Siemens Energy, Inc. | Sprayed skin turbine component |
US8347636B2 (en) | 2010-09-24 | 2013-01-08 | General Electric Company | Turbomachine including a ceramic matrix composite (CMC) bridge |
DE102011077620A1 (en) * | 2011-06-16 | 2012-12-20 | Rolls-Royce Deutschland Ltd & Co Kg | Component, useful in turbomachine and aircraft engine, comprises metallic coating provided on metallic base material, where metallic coating comprises adhesion zone connected with the metallic base material and structure zone |
US9056354B2 (en) | 2011-08-30 | 2015-06-16 | Siemens Aktiengesellschaft | Material system of co-sintered metal and ceramic layers |
US8999226B2 (en) | 2011-08-30 | 2015-04-07 | Siemens Energy, Inc. | Method of forming a thermal barrier coating system with engineered surface roughness |
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US20150030826A1 (en) * | 2013-07-26 | 2015-01-29 | Ahmed Kamel | Method for creating a textured bond coat surface |
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Also Published As
Publication number | Publication date |
---|---|
US7182580B2 (en) | 2007-02-27 |
EP1522604B1 (en) | 2007-02-14 |
DE50306521D1 (en) | 2007-03-29 |
EP1522604A1 (en) | 2005-04-13 |
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